GX16 and GX20 are two of the most widely used circular aviation connector series in industrial equipment, robotics, and automation. For buyers sourcing replacement pins or planning custom connectors, the difference between these two sizes matters — not just in diameter, but in pin capacity, current rating, and machined contact geometry. This guide compares GX16 vs GX20 connector pins so you can specify the right one for your application.
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GX16 vs GX20: The Basics
| Parameter | GX16 | GX20 |
|---|---|---|
| Shell diameter | 16 mm | 20 mm |
| Typical pin count | 2, 3, 4, 5, 6, 7, 8 | 2, 3, 4, 5, 6, 7, 8, 10, 12 |
| Typical pin diameter | 1.0 – 1.5 mm | 1.5 – 2.0 mm |
| Typical current rating | 5 – 10 A per contact | 10 – 16 A per contact |
| Contact material | Brass or copper, gold/silver plated | Brass or copper, gold/silver plated |
| Common use | Sensors, small motors, signal | Power, larger motors, mixed signal |
Pin Differences That Matter
Pin Diameter & Current Capacity
The most practical difference is pin cross-section. A GX16 pin is typically 1.0-1.5 mm in diameter, while GX20 pins run 1.5-2.0 mm. That larger cross-section translates directly into higher current capacity — roughly 5-10 A for GX16 contacts versus 10-16 A for GX20. If your application draws more than 10 A per contact, GX20 is the safer choice.
Pin Count & Contact Layout
GX16 connectors commonly support 2-8 pins. GX20 expands that range up to 10-12 pins in the same shell, because the larger shell gives more space between contact centers. This matters when you need more signals through one connector without increasing the number of cable runs.
Machined Contact Geometry
Both series use precision turned pins. The key geometry features are the contact tip (pin or socket), the solder or crimp tail, and the retention shoulder that locks the contact into the insulator. When machining replacement pins, the critical dimensions are pin OD, tail diameter, overall length, and shoulder position — all held to ±0.01 mm at VOLCRIX.
Which Should You Choose?
- Choose GX16 when space is tight, current is under 10 A per contact, and you need 2-8 signals.
- Choose GX20 when you need higher current (10-16 A), more pins (up to 12), or a more robust mechanical connection.
- Custom pins work with either: regardless of series, the contacts can be machined to your drawing — material, plating, and geometry are fully customizable.
Materials & Plating for GX Pins
Most GX connector pins are machined from brass (C3604) for general signal use, or copper alloys (C11000, C18150) for higher-current contacts. Plating is typically gold flash over nickel for low and stable contact resistance, or silver (2-5 µm) for high-current power contacts. At VOLCRIX we machine and plate to your spec, with Zeiss CMM inspection on every critical dimension.
Sourcing Custom GX Pins (Build-to-Print)
If you need replacement or custom pins for GX16, GX20, or other circular connector series, send us your drawing or a sample. We provide DFM feedback, material recommendations, and a quotation within 24 hours. Prototypes ship in 7-15 days; production runs in 3-4 weeks with full inspection reports.
Can a GX16 pin be used in a GX20 connector?
No. The pin geometry — including diameter, length, and retention features — is designed for a specific shell and insulator. Always machine or order pins that match your connector series and contact layout.
What current can a GX16 connector pin carry?
Typically 5-10 A per contact, depending on pin diameter, material, and ambient temperature. For higher current, choose GX20 or specify a larger custom pin.
Are GX16 and GX20 pins interchangeable with MIL-DTL-38999 contacts?
No. GX series are industrial circular connectors with their own contact geometry. MIL-DTL-38999 is a military specification with different dimensions, materials, and qualification requirements.
Can you machine gold-plated GX pins?
Yes. We machine the pin from brass or copper, then apply gold flash over nickel (0.76 µm min typical) or silver (2-5 µm) depending on your requirements.
What is the lead time for custom GX pins?
Prototypes in 7-15 days, production in 3-4 weeks after drawing approval. Rush options are available for urgent programs.
Related: custom aviation connector pin manufacturing
Related: MIL-DTL-38999 vs GX series comparison
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